Web and method for making fluid filled units

ABSTRACT

An elongate flattened thermoplastic tube has an inflation edge and an opposite edge. The tube includes spaced transverse seals that define sides of pouches. The tube includes lines of weakness that allow adjacent dunnage units to be separated. A frangible line of connection is disposed in one two superposed layers of the tube proximate to the inflation edge. This frangible connection may be broken to permit inflation of the inflatable pouches.

RELATED APPLICATIONS

The present application is a continuation application of U.S.application Ser. No. 15/040,447, filed Feb. 10, 2016, which is adivisional of U.S. application Ser. No. 13/739,049, filed Jan. 11, 2013,which is a divisional of U.S. application Ser. No. 12/259,419, filedOct. 28, 2008 which claims the benefit of U.S. Provisional patentapplication Ser. No. 60/983,940, filed Oct. 31, 2007 for WEB AND METHODFOR MAKING FLUID FILLED UNITS, the entire disclosures of which are fullyincorporated herein by reference.

FIELD OF THE INVENTION

The present application relates to fluid filled units and moreparticularly to plastic webs of interconnected pouches and to processesof converting interconnected pouches to fluid filled units.

BACKGROUND

Machines for forming and filling dunnage units from sheets of plasticare known. Machines which produce dunnage units by inflating preformedpouches in a preformed web are also known. For many applications,machines which utilize preformed webs are preferred.

Typically, the entire length of sides of adjacent dunnage units formedfrom a preformed web are connected by perforations. In prior art webs,these perforations extend all the way to an inflation edge of the web.

SUMMARY

The present invention relates to plastic webs of interconnected pouchesand processes of converting interconnected pouches to at least one rowof dunnage units. In one embodiment, the web is an elongate flattenedthermoplastic tube having an inflation edge and an opposite edge. Thetube includes spaced transverse seals that define sides of pouches. Afrangible line of connection is disposed in one superposed layers of thetube proximate to the inflation edge. This frangible connection may bebroken to permit inflation of the inflatable pouches.

Further advantages and benefits will become apparent to those skilled inthe art after considering the following description and appended claimsin conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a web for making fluid filled units;

FIG. 2 illustrates a web for making fluid filled units;

FIG. 2A illustrates a web for making fluid filled units;

FIG. 3 illustrates a web with pouches inflated and sealed to form fluidfilled units;

FIG. 4 illustrates a web for making fluid filled units;

FIG. 5 illustrates a web for making fluid filled units;

FIG. 6 illustrates a web for making fluid filled units;

FIG. 7A schematically illustrates a plan view of a process and machinefor converting web pouches to fluid filled units;

FIG. 7B schematically illustrates a plan view of a process and machinefor converting web pouches to fluid filled units;

FIG. 8A schematically illustrates an elevational view of the process andmachine for converting web pouches to fluid filled units;

FIG. 8B schematically illustrates an elevational view of the process andmachine for converting web pouches to fluid filled units;

FIG. 9 illustrates a process for converting web pouches to fluid filledunits;

FIG. 10 illustrates a web for making fluid filled units;

FIG. 10A illustrates a web for making fluid filled units;

FIG. 11 illustrates a web of pouches inflated and sealed to form fluidfilled units; and

FIG. 12 schematically illustrates a plan view of a cutter for openingthe inflation edge of a web.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, exemplary illustrations of webs 10 ofinflatable pouches 12 are shown. The webs 10 includes a top elongatedlayer of plastic 14 superposed onto a bottom layer of plastic 16. Thelayers are connected together along spaced edges, referred to as theinflation edge 18 and the opposite edge 20. In the example illustratedby FIG. 1, each edge 18, 20 is either a fold or a seal that connects thesuperposed layers 14, 16 along the edges 18, 20. The connection at theopposite edge 20 is illustrated as a hermetic seal and the connection atthe inflation edge 18 is illustrated as a fold in FIG. 1. However, thefold and the seal could be reversed or both of the connections could beseals in the FIG. 1 embodiment.

In the example illustrated by FIG. 2, the inflation edge 18 comprises afrangible connection 21 and the opposite edge 20 is a hermetic seal. Theillustrated frangible connection 21 is a line of perforations. The sizeof the perforations is exaggerated to clarify FIG. 2. The frangibleconnection 21 may be formed by folding the inflation edge 18 and pullingthe inflation edge over a serration forming wheel (not shown). FIG. 2Aillustrates a web 10 of inflatable pouches 12 in which a frangibleconnection 21′ is present in one of the superposed layers, in thedescribed embodiment layer 14, at a location offset from the inflationedge 18 by a distance D₄. In an exemplary embodiment, the distance D₄ isbetween 0.075 and 0.2 inches, in an exemplary embodiment between 0.09375and 0.15625 inches. The frangible connection can be formed in a widevariety of different ways any of which can be used. For example, thefrangible connection 21′ can be formed by pulling the web over aserration forming wheel (not shown) prior to folding the inflation edgeor by providing a serration backing plate (not shown) interposed betweenthe layers where the serration forming wheel contacts the web so thatonly a single layer is acted on by the wheel.

Referring to FIGS. 1, 2, 2A a plurality of longitudinally spaced,transverse seals 22 join the top and bottom layers 14, 16. Generally,each transverse seal 22 extends from the opposite edge 20 to within ashort distance of the inflation edge 18. Spaced pairs of lines ofperforations 24, 26 extend through the top and bottom layers terminatinga short distance from the edges 18, 20 respectively. A gap forming area28 extends between each associated pair of lines of perforations 24, 26.The gap forming area 28 opens to form a gap 13 when the pouches areinflated (see FIG. 3).

A gap forming area 28 denotes an area, preferably linear in shape, thatwill rupture or otherwise separate when exposed to a predeterminedinflation force. The magnitude of the inflation force is less than themagnitude of the force needed to rupture or separate the spaced apartlines of perforations 24, 26. The gap forming area 28 can take on anumber of embodiments, as will be discussed below. Any method thatproduces an area between the spaced apart lines of perforations 24, 26that ruptures or otherwise separates at a force lower than a forceneeded to rupture or separate spaced lines of perforations 24, 26 may beemployed to make the gap forming area 28.

Referring to FIG. 3, the web 10 of pouches 12 (FIGS. 1, 2, 2A) isinflated and sealed to form a row 11 of dunnage units 12′. The formeddunnage units 12′ are configured to be much easier to separate from oneanother than prior art arrays of dunnage units. In the exemplaryembodiment of FIG. 3, each adjacent pair of dunnage units 12′ isconnected together by a pair of spaced apart lines of perforations 24,26. The spaced apart lines of perforations 24, 26 are spaced apart by agap 13. A single row 11 of dunnage units 12′ can be graphicallydescribed as being in a “ladder” configuration. This configuration makesseparating two adjacent dunnage units 12′ much easier than separatingprior art arrays of dunnage units. To separate a pair of adjacentdunnage units 12, a worker simply inserts an object or objects, such asa hand or hands, into the gap 13 and pulls one dunnage unit 12′ awayfrom the other dunnage unit 12′. In the alternative, a mechanical systemcan be used to separate dunnage units 12′. A machine can be configuredto insert an object between adjacent dunnage units 12′ and apply a forceto separate the units

Referring to FIGS. 1-3, prior to conversion to a dunnage unit, a pouchis typically hermetically sealed on three sides, leaving one side opento allow for inflation. Once the pouch is inflated, the inflationopening is hermetically sealed and the dunnage unit is formed. Duringthe inflation process, as the volume of the pouch increases the sides ofthe pouch have a tendency to draw inward. Drawing the sides of thepouches inward will shorten the length of the sides of the pouch unlessthe sides of the pouch are constrained. In this application, the termforeshortening refers to the tendency of the length of a pouch side toshorten as the pouch is inflated. In prior art webs, the sides of thepouch are restrained, because sides of adjacent pouches are connected bylines of perforations that extend along the entire length of the pouchesand remain intact during and after inflation. The foreshortening of theunrestrained sides, such as the inflation opening, may not be uniform.Restraining the sides of adjacent connected pouches can causeundesirable inflation induced stresses. These undesirable stressescaused because sides of adjacent pouches are connected and restrained,thus, limiting inflation and causing wrinkles to develop in the layersat the unrestrained inflation opening. The wrinkles can extend into asection of the inflation opening to be sealed to complete the dunnageunit, which may comprise the seal. One reason the seal can becompromised is that wrinkling can cause sections of the layers 14, 16 tofold on top of one another. A sealing station of a dunnage machine istypically set to apply the appropriate amount of heat to seal two layersof material. The sealing of multiple layers of material in the area of awrinkle results in a seal that is weaker than remaining seal areas andmay result in a small leak or tendency to rupture at loads lower thanloads at which the dunnage units is designed to rupture.

In the embodiment illustrated by FIG. 3, the gap forming area 28,produces a gap 13 between adjacent pouches upon inflation. The gapallows foreshortening of the connected pouch sides and thereby reducesthe undesirable stresses that are introduced during inflation ascompared with prior art webs. In addition, the web with a gap 13facilitates fuller inflation of each pouch. The gap 13 maintains theinflation opening substantially free of wrinkles as the inflationopening is sealed to convert the inflated pouches to a dunnage units.

The illustrated web 10 is constructed from a heat sealable plastic film,such as polyethylene. The web 10 is designed to accommodate a processfor inflating each pouch 12 in the web to create a row or ladder 11 ofdunnage units 12′. The gap forming area 28 creates a gap 13 betweendunnage units 12′, which facilitate a efficient and effective processfor separating adjacent dunnage units 12′ in the row or ladder 11.

In the example illustrated by FIG. 4, the gap forming area 28 defined bythe web 10′ includes an easily breakable line of perforations 29 betweenthe spaced lines of perforations 24, 26. The force needed to rupture orseparate the line of perforations 29 is less than the force needed toseparate the perforations 24, 26 extending inward of the web edges 18,20. Each pair of perforations 24, 26 and associated more easilybreakable line of perforations 29 divide the transverse seal 22 into twotransverse sections. As a pouch 12 is inflated, the line of perforation29 begins to rupture or separate leading to the development of a gap 13between the produced dunnage units 12′ (See FIG. 3). Once the pouch 12is fully inflated, the line of perforations 29 is fully or nearly fullyruptured; however the perforations 24, 26 at the edges remain intact.These perforations 24, 26 are ruptured or separated when a worker orautomated process mechanically separates the perforations 24, 26.

FIG. 5 illustrates another embodiment of the web 10″. In this embodimentthe gap forming area 28 comprises an elongated cut 31 through bothlayers of material 14, 16. The cut 31 extends between each associatedpair of lines of perforations 24, 26. In the embodiment illustrated byFIG. 5, pairs 30 of transverse seals 22′ extend from the opposite edge20 to within a short distance of the inflation edge 18. Each of thepairs of lines of perforations 24, 26 and corresponding cuts 31 arebetween an associated pair of transverse seals 30. It should be readilyapparent that the seal 22 shown in FIG. 4 could be used with the cut 31shown in FIG. 5. It should also be readily apparent that the line ofperforations shown in FIG. 4 could be used with the transverse seals 22′shown in FIG. 5. It should be additionally apparent that any gap formingarea 28 can be used with either of the transverse seal configurations22, 22′ shown in FIGS. 4 and 5.

FIG. 6 illustrates a further embodiment of the web 10′″. In thisembodiment, the gap forming area 28 comprises at least two elongatedcuts 32, separated by light connections of plastic 36, also referred toas “ticks.” These connections 36 hold transverse edges 38, 40 of thepouches 12 together to ease handling of the web 10, such as handlingrequired during installation of the web 10 into a dunnage machine. Asthe pouches 12 are inflated, the connections 36 rupture or otherwisebreak resulting in a gap 13 between the spaced pairs of perforations 24,26. This gap 13 allows for full inflation and reduces the stresses inthe layers at the seal site normally caused by the foreshortening andrestrictions on foreshortening of webs in the prior art. The reducedstress in the layers inhibits wrinkles along the inflation opening to besealed.

Other methods of creating a gap forming area not specifically disclosedare with the scope of the present application. Any area that separatesand forms a gap between adjacent pouches as pouches 12 in a web 10 areinflated are contemplated by this disclosure.

FIG. 3, illustrates a length of the web 10, 10′, 10″ or 10′″ after ithas been inflated and sealed to form dunnage units 12′. An inflationseal 42, the transverse seals 22 and an opposite edge seal 44hermetically seal the top and bottom layers. The side edges 38, 40 ofthe formed dunnage units are separated to form a gap 13. Each pair ofadjacent dunnage units 12′ are connected together by the pair of spacedapart lines of perforations 24, 26. The gap 13 extends between the pairof spaced apart lines of perforations 24, 26. The array of dunnage units12′ is a single row of dunnage units in a “ladder” configuration. Thelines of perforations 24, 26 are configured to be easily breakable by aworker or automated system. To separate a pair of adjacent units 12′, aworker inserts an object, such as the worker's hand or hands into thegap 13. The worker then grasps one or both of the adjacent dunnage units12′ and pulls the adjacent dunnage units 12′ relatively apart asindicated by arrows 43 a, 43 b. The lines of perforation 24, 26 ruptureor otherwise separate and the two adjacent dunnage units 12′ areseparated. The existence of the gap 13 also results in reduced stressesin the area of the inflation seal 42 at the time of sealing andaccommodates increased inflation volume of the dunnage units 12′ ascompared with prior inflated dunnage units.

In one embodiment, the line of perforations 24 that extends from theopposite edge 20 is omitted. In this embodiment, the gap forming area 28extends from the inflation edge line of perforations 26 to the oppositeedge. In this embodiment, the gap 13 extends from the inflation edgeline of perforations 26 to the opposite edge 20.

The connection of the layers 14, 16 at the inflation edge 18 can be anyconnection that is maintained between layers 14, 16 prior to the web 10being processed to create dunnage units 12′. In the embodimentillustrated by FIGS. 1 and 2A, the connection is a fold. In theembodiment illustrated by FIG. 2, the connection is a line ofperforations 21. One method of producing such a web is to fold acontinuous layer of plastic onto itself and create a fold at what is tobecome the inflation edge 18, A tool can be placed in contact with thefold to create a line of perforation. The opposite edge 20 can behermetically sealed and the transverse hermetic seals 22 can be addedalong with the separated lines of perforations 24, 26 extending inwardfrom the inflation and opposite edges 18, 20. The web shown in FIG. 1can be produced in the same manner, except the perforations are notadded.

FIGS. 7A, 7B, 8A, 8B and 9 schematically illustrate a machine 50 andprocess of converting the webs 10, 10′, 10″ and 10′ to dunnage units12′. Referring to FIGS. 7A, 7B, 8A and 8B, a web 10, 10′, 10″ or 10′″ isrouted from a supply 52 (FIGS. 8A and 8B) to and around a pair ofelongated, transversely extending guide rollers 54. The guide rollers 54keep the web taught as the web 10 is pulled through the machine 50. Atlocation A, the web pouches are uninflated. In the embodimentillustrated by FIG. 5, pouch edges 38, 40 defined by the cut 31 areclose to one another at location A. In the embodiments illustrated byFIGS. 4 and 6, the frangible connections 29, 36 are of sufficientstrength to remain intact at location A.

A longitudinally extending guide pin 56 is disposed in the web atstation B. The guide pin 56 is disposed in a pocket bounded by the topand bottom layers 14, 16, the inflation edge 18, and ends of thetransverse seals 22. The guide pin 56 aligns the web as it is pulledthrough the machine. A separator, such as a knife cutter 58 (FIGS. 7Aand 8A), or a blunt surface 58′ (FIGS. 7B and 8B) is present on theguide pin 56. In the embodiment illustrated by FIGS. 7A and 8A the knifecutter 58 extends from the guide pin 56. The knife cutter 58 is used tocut the inflation edge 18 illustrated by FIG. 1, but could also be usedto cut the perforated inflation edge 18 illustrated by FIG. 2. Thecutter 58 slits the inflation edge 18 as the web moves through themachine 50 to provide inflation openings 59 (See FIG. 9) into thepouches, while leaving the pouches otherwise imperforate. A variation ofthis would have the cutter 58 cutting either layer 14, 16, or both nearthe inflation edge 18. In the embodiment illustrated by FIGS. 7B and 8B,the guide pin 56 defines a separator in the form of the blunt surface58′ and the knife cutter is omitted. The blunt surface 58′ is used tobreak the perforated inflation edge illustrated by FIG. 2. The bluntsurface 58′ breaks open the inflation edge 18 as the web moves throughthe machine to provide the inflation openings into the pouches 12.

A blower 60 is positioned after the cutter 58 or blunt surface 58′ instation B. The blower 60 inflates the web pouches as the web moves pastthe blower. Referring to FIG. 9, the web pouches are opened and inflatedat station B. The seal edges 38, 40 spread apart as indicated by arrows61 (FIGS. 7A, 7B and 9) as the web pouches are inflated. In theembodiment illustrated by FIGS. 4 and 6, the frangible connections 29,36 maintain successive pouches substantially aligned as the web is fedto the filling station B. The frangible connections are sufficientlyweak that the connection between a pouch that has been opened forinflation and is being inflated at the fill station B and an adjacent,successive (or preceding) pouch will rupture as the pouch at the fillstation is inflated. The spreading of the edges 38, 40 forms a row ofinflated dunnage units in a ladder configuration and increases thevolume of the air that can enter the pouches. The spreading also reducesthe stresses imparted to the web adjacent the inflation side edge 18where it is to be sealed.

The inflation seal 42 is formed at station C by a sealing assembly 62 tocomplete each dunnage unit. In the exemplary embodiment, the inflatedvolume of the pouches is maintained by continuing to blow air into thepouch until substantially the entire length of the inflation opening 59is sealed. In the example of FIGS. 8A, 8B and 9, the blower 60 blows airinto a pouch being sealed up to a location that is a short distance D₁from closing position where the sealing assembly 62 pinches the top andbottom layers 14, 16 to maintain the inflated volume of the pouches.This distance D₁ is minimized to minimize the volume of air that escapesfrom the inflated pouch before the trailing transverse seal of theinflated pouch reaches the closing position. For example, the distanceD₁ may be 0.250 inches or less, to blow air into the inflation openingunit the trailing transverse seal is within 0.250 inches of the closingposition.

In the examples illustrated by FIGS. 8A and 8B, the sealing assemblyincludes a pair of heated sealing elements 64, a pair of coolingelements 66, a pair of drive rollers 68, and a pair of drive belts 70.In an alternate embodiment, the pair of cooling elements is omitted.Each belt 70 is disposed around its respective heat sealing element 64,cooling element 66 (if included), and drive roller 68. Each belt 70 isdriven by its respective drive roller 68. The belts 70 are in closeproximity or engage one another, such that the belts 70 pull the web 10through the heat sealing elements 64 and the cooling elements 66. Theseal 42 is formed as the web 10 passes through first the heated sealingelements 64 and then a heat sink such as the cooling elements. Onesuitable heating element 64 includes heating wire 80 carried by aninsulating block 82. Resistance of the heating wire 80 causes theheating wire 80 to heat up when voltage is applied. The cooling elements66 cool the seal 42 as the web 10 is pulled between the coolingelements. One suitable cooling element is an aluminum (or other heatsinkmaterial) block that transfers heat away from the seal 42. Referring toFIG. 9, the spreading of the edges 38, 40 greatly reduces the stressimparted on the web material at or near the seal 42. As a result, a muchmore reliable seal 42 is formed.

FIGS. 10-12 show another embodiment of a web 10. In this embodiment, thespaced apart lines of perforations 26 extending from the inflation edge,as shown in FIGS. 1-7B and 9, is replaced with a modified line ofperforations 90. As best seen in FIG. 10, a starting point 89 of theline of perforations 90 begins a distance D₂ from the inflation edge 18and extends away from and generally perpendicular to the inflation edge18. As can be seen in FIG. 10A, in an embodiment in which a frangibleconnection 21′ (also shown in FIG. 2A) is offset from the inflation edge18 by a distance D₄, the distance D₂ is greater than the distance D₄.Hence, in the examples illustrated by FIGS. 10-12, the line ofperforations 90 extends to a gap forming area 28 and an opposite edgeline of perforations 24 extends to the opposite edge. In anotherembodiment, the gap forming area 28 is not included and the line ofperforations 90 extends all the way or nearly all the way to theopposite edge.

The distance D₂ is selected to prevent the cutter (FIG. 12) fromengaging the line of perforations in the exemplary embodiment. Althoughdistance D₂ may vary based on the particular cutter implemented, in oneembodiment, distance D₂ is approximately 0.25 to 0.375 inch in length.FIG. 11 illustrates a row of inflated dunnage units. The elimination ofperforations extending to the inflation edge 18 does not make itsubstantially harder to separate adjacent dunnage units in the row 11 ofdunnage units 12′ in the exemplary embodiment. The dunnage units 12′ canstill be separated by inserting an object or objects, such as a hand orhands, into the gap 13 and pulling one dunnage unit 12′ away from anadjacent dunnage unit 12′. When the dunnage units are pulled apart, thethin web of material between the starting point 89 and the inflationedge easily breaks.

The process of forming perforations through the top and bottom layers ofplastic 14, 16, as the web 10 is formed, may cause the top and bottomlayers 14, 16 to be adhere or be held together at the line of aperforations. When the lines of perforations extend all the way to theinflation edge and the cutter 58 cuts on one side of the inflation edge,the cutter will engage each line of perforations. Engagement of thelines of perforations by the cutter may cause the web to bind, wrinkle,bunch up, or gather around the edge of the cutter until the cutterpasses the line of perforations and begins cutting the web again. In theembodiment illustrated by FIGS. 10-12, engagement of the line ofperforations 90 with the cutter is eliminated by beginning the line ofperforations 90 a distance D₂ away from the inflation edge 20. Asillustrated in FIG. 12, the tip of a cutter 58 utilized in opening theinflation edge 20 is positioned a distance D₃ past the inflation edge 20as the edge is opened. The distance D₂ that the line of perforations 90is away from the inflation edge 20 is configured to be greater that thedistance D₃ to which the tip of a cutter 58 is positioned past theinflation edge 20. As a result, the cutter 58 will not engage the linesof perforations. Likewise, in the case of the frangible connection 21′shown in 10A, the cutter 58 or blunt surface 58′ (FIG. 7B) that opensthe offset frangible connection 21′ will not engage the lines ofperforations 90. This eliminates the possibility that the cutter orblunt surface could engage the lines of perforations and cause the webto bunch up or gather around the cutter 58 or blunt surface 58′ as thecutter 58 opens the inflation edge.

The present invention is not to be considered limited to the preciseconstruction disclosed. Various modifications, adaptations and uses mayoccur to those skilled in the art to which the invention relates. Allsuch modifications, adaptations, and uses fall within the scope orspirit of the claims.

The invention claimed is:
 1. A method of forming dunnage units, themethod comprising: providing a preformed flattened tubular webcomprising: a first elongated layer; a second elongated layer superposedover the first elongated layer, the first and second layers connectedtogether at an inflation edge; a frangible line of connection disposedin only one of the first and second layers, the frangible line ofconnection being substantially parallel to the inflation edge and offsetfrom the inflation edge by a first distance; a plurality of transverseseals extending to a seal termination point that is a second distancefrom the inflation edge, wherein the second distance is greater than thefirst distance; a plurality of inflatable pouches defined by the firstand second elongated layers, the inflation edge, and the transverseseals; and a plurality of lines of weakness that allow the inflatablepouches to be separated, the lines of weakness beginning at a startingpoint transversely located between the inflation edge and thetermination point of the transverse seals; positioning a separator withrespect to the web, such that the separator engages the frangible lineof connection in only one of the first and second layers; opening thefrangible line of connection in only one of the two layers with theseparator; inflating the inflatable pouches to an inflated volume; andsealing the inflated pouches to convert the inflated pouches to dunnageunits.
 2. The method of claim 1, wherein inflating the inflatablepouches to the inflated volume causes a gap to form between the inflateddunnage units.
 3. The method of claim 1, wherein the step of positioninga separator is performed by positioning a cutter such that it engagesthe frangible line of connection.
 4. The method of claim 1, wherein thestep of positioning a separator is performed by positioning a bluntsurface such that it engages the frangible line of connection.
 5. Themethod of claim 1, wherein the lines of weakness comprise perforations.6. The method of claim 1, wherein the lines of weakness comprise one ormore cuts.
 7. The method of claim 1, wherein the lines of weaknesscomprise a combination of cuts and perforations.
 8. The method of claim1, wherein the starting point is between 0.250 inches and 0.375 inchesfrom the inflation edge.
 9. The method of claim 1, wherein the startingpoint is selected such that the lines of weakness clear a cutter thatcuts the inflation edge to open the pouches for inflation.
 10. Themethod of claim 1, wherein the starting point is selected such that webbetween the starting point and the inflation edge breaks upon pullingadjacent dunnage units apart.
 11. The method of claim 1, wherein thefirst distance is between 0.09375 inches and 0.15625 inches from theinflation edge.
 12. The method of claim 1, wherein the lines of weaknessextend to an opposite edge of the web.
 13. The method of claim 1,further comprising a plurality of opposite side lines of weakness formedin both the first and second elongated layers that extend from anopposite edge of the web toward the lines of weakness that begin at thestarting point.
 14. The method of claim 13, further comprising aplurality of gap forming lines extending between the lines of weaknessthat begin at the starting point and the opposite side lines ofweakness, wherein the gap forming lines are configured such that the webseparates along the gap forming lines when the pouches are inflated. 15.The method of claim 14, wherein the gap forming lines comprise a cutthrough the first and second layers.
 16. The method of claim 15, furthercomprising a tick that holds edges of the first and second layersdefined by the cut together until inflation of the inflatable pouches.17. The method of claim 14, wherein the gap forming lines comprise linesof perforations.
 18. The method of claim 17, wherein the lines ofperforations that form the gap forming lines are more easily broken thanthe lines of weakness that begin at the starting point.